Komatsu 210M Dump Truck Shop Manual DG715 – PDF DOWNLOAD 

Description

Komatsu 210M Dump Truck Shop Manual DG715 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 210M Dump Truck Shop Manual DG715 – PDF DOWNLOAD 

Language : English
Pages : 475
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu 210M Dump Truck Shop Manual DG715 – PDF DOWNLOAD 

MAIN MENU 0
COVER PAGE 1
TABLE OF CONTENTS 7
GENERAL INFORMATION 9
TRUCK COMPONENT DESCRIPTION AND SPECIFICATIONS 11
GENERAL SAFETY AND TRUCK OPERATION 15
WARNINGS AND CAUTIONS 37
CHARTS AND TABLES 43
STORAGE PROCEDURES 49
STRUCTURES 69
STRUCTURAL COMPONENTS 71
COWL AND HOOD 71
DECKS 71
RIGHT DECK STRUCTURE 71
REMOVAL 71
INSTALLATION 71
INSPECTION 72
DUMP BODY 73
DUMP BODY 73
REMOVAL 73
INSTALLATION 74
BODY PIVOT PINS AND SPACERS 74
REMOVAL 74
INSTALLATION 74
BODY-UP PIN 75
INSTALLATION 75
BODY PAD 75
ROCK EJECTORS 76
INSPECTION 76
BODY POSITION INDICATOR 76
LINER PLATES/BODY REPAIR 76
BODY-UP LIMIT SWITCH 76
ADJUSTMENT 76
MAINTENANCE 78
FUEL TANK 79
FUEL TANK 79
REMOVAL 79
INSTALLATION 80
CLEANING 80
VENT 80
GAUGE 80
REMOVAL 80
INSTALLATION 80
ENGINE, FUEL, COOLING AND AIR CLEANER 81
COOLING SYSTEM 83
RADIATOR 83
REMOVAL 83
INSTALLATION 85
REPAIR 86
HEAT EXCHANGER 86
REMOVAL 86
INSTALLATION 87
REPAIR 87
ENGINE 89
ENGINE 89
REMOVAL 89
INSTALLATION 90
REPAIR 92
AIR FILTRATION SYSTEM 93
AIR CLEANER 93
SERVICE CHECKS 93
FILTER ELEMENT REPLACEMENT 93
MAIN FILTER ELEMENT 93
REMOVAL 93
INSTALLATION 93
MAIN FILTER ELEMENT CLEANING 95
PRECLEANER SECTION 96
CLEANING PRECLEANER TUBES 96
AIR INTAKE TROUBLESHOOTING 97
ENGINE COMPONENTS 99
FAN 99
REMOVAL 99
INSTALLATION 99
FAN BELT 99
REPLACEMENT 99
ADJUSTMENT 100
ALTERNATOR BELT ADJUSTMENT 100
ELECTRIC SYSTEM (24 VDC NON PROPULSION) 103
24VDC ELECTRICAL SUPPLY SYSTEM 105
ELECTRICAL SYSTEM DESCRIPTION 105
BATTERY 105
SERVICE 105
STORAGE 105
MAINTENANCE AND TROUBLESHOOTING 106
SPILLAGE 107
BATTERY CHARGING ALTERNATOR 107
OPERATION 107
MAGNETIZING THE ROTOR 109
REGULATOR ADJUSTMENT 109
CIRCUIT CHECKOUT 109
BATTERY CHARGING CIRCUIT COMPONENTS 109
BATTERY EQUALIZER 110
PURPOSE 110
TROUBLESHOOTING 110
MONITOR 111
ELECTRICAL SYSTEM COMPONENTS 113
ELECTRICAL CIRCUIT CHECKOUT 113
HORN, WINDSHIELD WIPER, AND WINDSHIELD WASHER CIRCUITS 113
WINDSHIELD WASHER CIRCUIT 113
WINDSHIELD WIPER CIRCUIT CHECKOUT PROCEDURE 113
BRAKE LOCK AND PARK BRAKE CIRCUIT 114
BRAKE LOCK SWITCH CIRCUIT 114
BRAKE LOCK CHECKOUT 114
PARK BRAKE SWITCH AND CIRCUIT 114
PARK BRAKE CHECKOUT 114
LOW BRAKE PRESSURE SWITCH AND CIRCUIT 114
GAUGES AND CIRCUIT COMPONENTS 114
CIRCUIT COMPONENTS 115
LOW BRAKE PRESSURE WARNING AND INDICATOR LIGHT CIRCUITS 115
CIRCUIT COMPONENTS 115
HOIST CONTROL CIRCUIT 117
HOIST CONTROL SWITCH CIRCUIT CHECKOUT 117
BODY-UP LIMIT SWITCH 117
BODY-UP LIMIT SWTICH CIRCUIT CHECKOUT 117
STEERING BLEEDDOWN TIMER CIRCUIT 117
CIRCUIT COMPONENTS 118
STEERING BLEEDDOWN CIRCUIT CHECKOUT 118
ACCUMULATOR PRECHARGE CIRCUIT 118
LIGHT CIRCUIT 118
CIRCUIT COMPONENTS 118
CIRCUIT CHECKOUT 119
HEATER AND AIR CONDITIONER CIRCUIT 119
CIRCUIT COMPONENTS 119
CIRCUIT CHECKOUT 119
24 VDC ELECTRIC START SYSTEM 120
OPERATION 120
OPERATION 120
CRANKING MOTOR 120
REMOVAL 120
INSTALLATION 120
CRANKING MOTOR TROUBLESHOOTING 121
PRELIMINARY INSPECTION 121
NO-LOAD TEST 121
INTERPRETING RESULTS OF TESTS 121
DISASSEMBLY 122
CLEANING AND INSPECTION 124
ARMATURE SERVICING 124
FIELD COIL CHECKS 124
FIELD COIL REMOVAL 124
SOLENOID CHECKS 125
ASSEMBLY 126
PINION CLEARANCE 126
MAGNETIC SWITCH 127
REMOVAL 127
INSTALLATION 127
COIL TEST 127
ELECTRIC START SYSTEM WIRING DIAGRAMS 128
STARTER, ENGINE 24 VDC 129
CIRCUIT CHECK – OUT 129
COMMERCIAL ELECTRONIC CONTROL (CEC) 131
ELECTRONIC THROTTLE PEDAL 131
ADJUSTMENT 131
REMOVAL 131
INSTALLATION 131
DISASSEMBLY 132
ASSEMBLY 132
CEC SYSTEM OPERATION 133
RANGE SELECTOR 133
“DO NOT SHIFT” LIGHT 133
“CHECK TRANS” LIGHT 134
SYSTEM DESCRIPTION 134
TRANSMISSION CONTROL CIRCUITS 135
BATTERY CHARGING CIRCUIT 135
CONTROL POWER AND MEMORY CIRCUITS 136
START CIRCUIT 136
CHECK TRANSMISSION WARNING LIGHT CIRCUIT 136
BACKUP HORN AND LIGHT CIRCUIT 136
HOIST INTERLOCK CIRCUIT 136
AUTO/MANUAL CIRCUIT 136
OVERSPEED RELAY CIRCUIT (NOT USED) 136
SPEEDOMETER CIRCUIT 137
TRANSMISSION CIRCUIT COMPONENTS 138
CIRCUIT DESCRIPTION AND CHECKOUT 139
CEC DIAGNOSTIC CODES 142
TRANSMISSION AND PTO 143
TRANSMISSION 145
TRANSMISSION 145
TRANSMISSION REMOVAL 145
TRANSMISSION INSTALLATION 146
TRANSMISSION FILL INSTRUCTION 147
TRANSMISSION FILTER 148
SERVICE 148
TRANSMISSION OIL COOLER 149
REMOVAL AND INSTALLATION 149
REPAIR 149
POWER TAKE OFF (PTO) 151
PTO GEAR BOX 151
REMOVAL 151
INSTALLATION 151
DISASSEMBLY 153
ASSEMBLY 153
DRIVELINES & U-JOINTS 155
REMOVAL 155
INSTALLATION 155
DISASSEMBLY 155
ASSEMBLY 156
DRIVE AXLE, SPINDLES AND WHEELS 157
TIRES AND RIMS 159
TIRES AND RIMS 159
GENERAL INFORMATION 159
TIRE REMOVAL FROM RIM 160
TIRE INSTALLATION ON RIM 160
FRONT TIRES AND RIMS 161
REMOVAL 161
INSTALLATION 161
REAR TIRE AND RIM 162
REMOVAL 162
INSTALLATION 162
TIRE MATCHING 163
FRONT WHEEL HUB AND SPINDLES 165
FRONT WHEEL HUB 165
REMOVAL 165
FRONT WHEEL BEARING AND BRAKE DISC REPLACEMENT 166
FRONT WHEEL HUB INSTALLATION AND BEARING ADJUSTMENT 166
FRONT WHEEL SPINDLE REMOVAL 167
FRONT WHEEL SPINDLE INSTALLATION 168
STEERING LINKAGE REMOVAL 169
STEERING LINKAGE BALL STUD AND BEARING REMOVAL 169
FRONT WHEEL TOE-IN ADJUSTMENT 170
BIAS PLY TIRES 170
RADIAL TIRES 170
FINAL DRIVE ATTACHMENTS 171
FINAL DRIVE ANCHOR 171
PIN REMOVAL 171
PIN INSTALLATION 172
BEARING REMOVAL AND INSPECTION 172
BEARING INSTALLATION 172
PANHARD ROD 172
REMOVAL 172
INSTALLATION 172
BEARING REPLACEMENT 173
FINAL DRIVE ASSEMBLY 175
COMPLETE FINAL DRIVE ASSEMBLY 175
REMOVAL 175
INSTALLATION 176
DIFFERENTIAL CARRIER ASSEMBLY – SERVICE WITH COMPLETE FINAL DRIVE ASSEMBLY REMOVED FROM UNDER TRUCK 177
REMOVAL 177
INSTALLATION 178
DIFFERENTIAL CARRIER ASSEMBLY – SERVICE WITH FINAL DRIVE IN PLACE UNDER TRUCK 179
REMOVAL 179
INSTALLATION 180
DIFFERENTIAL CAGE REMOVAL 181
PINION REMOVAL 181
DIFFERENTIAL CAGE DISASSEMBLY 181
SPIDER GEAR BEARING REMOVAL 182
CLEANING AND INSPECTION 183
SPIDER GEAR BEARING INSTALLATION 183
DIFFERENTIAL CAGE ASSEMBLY 183
PINION INSTALLATION AND BEARING ADJUSTMENT 184
DIFFERENTIAL CAGE INSTALLATION 185
CARRIER BEARING AND BACKLASH ADJUSTMENT 186
FINAL DRIVE PLANETARIES AND WHEEL HUBS 187
PLANETARY DRIVE 187
PLANETARY DRIVE REMOVAL 187
PLANETARY REACTOR AND RING GEAR REMOVAL 188
PLANETARY REACTOR AND RING GEAR INSTALLATION 188
CLEANING AND INSPECTION 189
PLANETARY DRIVE INSTALLATION 189
PLANETARY CARRIER DISASSEMBLY 189
PLANETARY CARRIER ASSEMBLY 190
WHEEL HUB AND BEARINGS 190
REMOVAL 190
BEARING REPLACEMENT 190
INSTALLATION 191
HYDRAIR SUSPENSIONS 195
FRONT SUSPENSIONS 197
FRONT SUSPENSIONS 197
REMOVAL 197
INSTALLATION 198
DISASSEMBLY 199
INSPECTION 199
ASSEMBLY 200
REAR SUSPENSIONS 201
REAR SUSPENSIONS 201
REMOVAL 201
INSTALLATION 202
DISASSEMBLY 202
ASSEMBLY 203
REAR SUSPENSION SPHERICAL BEARING REPAIR 204
DISASSEMBLY 204
INSPECTION 204
ASSEMBLY 204
OIL AND CHARGING PROCEDURES 205
GENERAL 205
EQUIPMENT LIST 205
HYDRAIR SERVICE KIT 205
INSTALLATION OF CHARGING KIT 205
REMOVAL OF CHARGING KIT 206
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 206
FRONT SUSPENSION 206
FRONT SUSPENSION OILING 206
FRONT SUSPENSION NITROGEN CHARGING 207
REAR SUSPENSION 208
REAR SUSPENSION OILING 208
REAR SUSPENSION NITROGEN CHARGING 209
OIL AND NITROGEN SPECIFICATIONS CHART 210
BRAKE CIRCUIT 211
BRAKE CIRCUIT 213
CIRCUIT OPERATION 213
CHARGING 213
MANUAL APPLICATION 214
HYDRAULIC OIL MANIFOLD 214
BRAKE ACCUMULATORS 214
ACCUMULATOR PRECHARGE 214
LOW-PRESSURE BRAKE DETECTION MODULE 214
LOW-PRESSURE SENSING SHUTTLE VALVE 214
BRAKE ACCUMULATOR PRESSURE CHECKS 214
ACCUMULATOR SHUTTLE VALVE 215
ACCUMULATOR DISCHARGE VALVES (BLEEDDOWN VALVES) 215
EMERGENCY APPLY VALVE 215
BRAKE PRESSURE WARNING SWITCH 215
BRAKE MANIFOLD 215
BRAKE LOCK SHUTTLE VALVE 215
BRAKE LOCK SOLENOID VALVE 216
BRAKE MANIFOLD SHUTTLE VALVE 216
STEERING BLEEDDOWN SOLENOID VALVE 216
STEERING ACCUMULATOR PRESSURE CHECK 216
SERVICE BRAKE TREADLE VALVE 216
RETARDER TREADLE VALVE 216
SERVICE BRAKE/RETARDER SHUTTLE VALVE 217
STOP LIGHT MANIFOLD AND TEE 217
REAR BRAKE SHUTTLE VALVES 217
WET DISC BRAKE ASSEMBLY 217
BRAKE CIRCUIT COMPONENT SERVICE 219
LOW PRESSURE BRAKE DETECTION MODULE 219
BRAKE MANIFOLD 219
BRAKE ACCUMULATOR REPAIR 220
SERVICE BRAKE TREADLE VALVE REPAIR 220
REMOVAL 220
INSTALLATION 221
DISASSEMBLY OF TREADLE VALVE ASSEMBLY 221
REMOVAL OF BRAKE MANIFOLD 221
BRAKE VALVE DISASSEMBLY 223
ASSEMBLY OF TREADLE VALVE ASSEMBLY 223
BRAKE VALVE ASSEMBLY 223
INSTALLATION OF BRAKE MANIFOLD 225
ADJUSTMENT FOR MAXIMUM DELIVERY PRESSURE 225
BRAKE PEDAL ADJUSTMENT 227
SERVICE BRAKE TREADLE PEDAL 228
PEDAL DISASSEMBLY 228
PEDAL ASSEMBLY 228
RETARDER TREADLE VALVE 229
REMOVAL 229
INSTALLATION 229
DISASSEMBLY 229
ASSEMBLY 231
RETARDER TREADLE PEDAL DISASSEMBLY 232
RETARDER TREADLE PEDAL ASSEMBLY 232
BRAKE CIRCUIT CHECKOUT PROCEDURE 233
CIRCUIT TRACKING 233
INITIAL SYSTEM SET-UP 234
CHECK OF BRAKE CIRCUIT SHUTTLE VALVES 237
BRAKE SYSTEM CHECKOUT 241
FAILURE MODE CHECKOUT 234
BRAKE VALVE LEAKAGE 234
TROUBLESHOOTING 237
CHECKOUT DATA SHEET 241
FRONT WHEEL SPEED DISC BRAKES 243
LINING REPLACEMENT 243
LINING REPLACEMENT ON TRUCK 243
BRAKE CALIPER REPAIR 244
REMOVAL 244
INSTALLATION 244
PISTON AND SEAL REMOVAL 244
PISTON AND SEAL INSTALLATION 245
BRAKE CALIPER BENCH TEST 245
FRONT BRAKE BLEEDING PROCEDURE 246
FRONT SERVICE BRAKE BURNISHING PROCEDURE 246
REAR WET DISC BRAKE ASSEMBLY 249
WET DISC BRAKE ASSEMBLY 249
REMOVAL 249
INSTALLATION 250
WET DISC BRAKE DISASSEMBLY 251
BRAKE PISTON DISASSEMBLY 254
BRAKE PISTON INSPECTION 254
BRAKE PISTON ASSEMBLY 254
FLOATING RING SEAL ASSEMBLY/INSTALLATION 255
WET DISC BRAKE ASSEMBLY 259
REAR WET DISC BRAKE BLEEDING PROCEDURE 261
REAR BRAKE DISC WEAR INDICATOR 262
REMOVAL/INSTALLATION FROM ONE BRAKE TO ANOTHER 262
PARK BRAKE 263
PARKING BRAKE 263
REMOVAL/INSTALLATION 263
PARK BRAKE LINING ADJUSTMENT 263
PARK BRAKE LINKAGE ADJUSTMENT 263
PARK BRAKE ACTUATOR ASSEMBLY REPAIR 264
REMOVAL 264
INSTALLATION 264
DISASSEMBLY 265
ASSEMBLY 265
ACTUATOR SPRING POD DISASSEMBLY 265
ACTUATOR SPRING POD ASSEMBLY 266
PARK BRAKE BURNISHING 266
HYDRAULIC SYSTEM 267
HYDRAULIC SYSTEM 269
HYDRAULIC SYSTEM DESCRIPTION 269
HYDRAULIC SYSTEM COMPONENT REPAIR 273
TANDEM HYDRAULIC PUMP 273
REMOVAL 273
REMOVAL 273
INSTALLATION 273
PUMP DISASSEMBLY 274
PUMP ASSEMBLY 276
CARTRIDGE DISASSEMBLY 277
INSPECTION 277
CARTRIDGE ASSEMBLY 279
HYDRAULIC TANK 281
FILLING INSTRUCTIONS 281
REMOVAL 281
INSTALLATION 282
HYDRAULIC TANK RELIEF CHECK VALVE 282
HYDRAULIC TANK BREATHER 283
HYDRAULIC FILTERS 283
REMOVAL 284
REMOVAL 284
INSTALLATION 284
DIFFERENTIAL PRESSURE SWITCH TESTING 285
TEST PROCEDURES 285
STEERING CIRCUIT 287
STEERING CIRCUIT OPERATION 287
STEERING CIRCUIT COMPONENT DESCRIPTION 287
STEERING CONTROL VALVE 291
REMOVAL 291
INSTALLATION 291
DISASSEMBLY 292
CLEANING AND INSPECTION 295
ASSEMBLY 295
ALTERNATE METHOD 295
STEERING CIRCUIT COMPONENT REPAIR 299
ACCUMULATORS 299
REMOVAL 299
INSTALLATION 300
DISASSEMBLY 300
CLEANING AND INSPECTION 300
ASSEMBLY 300
LOW PRESSURE ACCUMULATOR PRESSURE SWITCH 301
ACCUMULATOR CHARGING PROCEDURE 302
INLINE FILTERS 303
SERVICE 303
STEERING CYLINDERS 304
DISASSEMBLY 304
ASSEMBLY 304
BRAKE/STEERING PUMP REPAIR 305
BRAKE/STEERING PUMP REPAIR 305
REMOVAL 305
INSTALLATION 305
SHAFT SEAL REPLACEMENT 306
PUMP DISASSEMBLY 308
PUMP ASSEMBLY 312
CONTROL (COMPENSATOR) VALVE 314
HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION 317
CIRCUIT OPERATION 317
HOIST VALVE 317
AUXILIARY MANIFOLD 318
COUNTER-BALANCE VALVE 318
HOIST CYLINDERS 318
CHECK VALVES 318
HOIST CIRCUIT COMPONENT REPAIR 319
HOIST VALVE 319
REMOVAL 319
INSTALLATION 319
DISASSEMBLY 320
ASSEMBLY 321
HOIST CYLINDER 322
REMOVAL 322
INSTALLATION 322
DISASSEMBLY 324
CLEANING AND INSPECTION 324
ASSEMBLY 324
HOIST CYLINDER MOUNTING BEARING REPLACEMENT 324
HYDRAULIC CHECK-OUT PROCEDURE 325
GENERAL INFORMATION 325
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 325
INITIAL SYSTEM-SET UP 325
ACCUMULATOR AND BRAKE/STEERING PUMP CHECKS 325
STEERING VALVE LEAKAGE CHECK 327
STEERING CYLINDER LEAKAGE CHECK 327
TROUBLESHOOTING CHART (STEERING SYSTEM) 328
HOIST CIRCUIT CHECKOUT & ADJUSTMENT PROCEDURE 330
AUXILIARY VALVE 330
PRESSURE CHECK 330
LEAKAGE CHECK 330
CHECKING AND ADJUSTING HOIST SYSTEM PRESSURE RELIEF VALVE 331
CHECKING AND ADJUSTING “POWER DOWN” PRESSURE 331
TROUBLESHOOTING CHART (HOIST SYSTEM) 332
STEERING SYSTEM DATA SHEET 335
HOIST SYSTEM DATA SHEET 336
HYDRAULIC SYSTEM FLUSHING PROCEDURE 337
OPTIONS AND SPECIAL TOOLS 339
LINCOLN AUTOMATIC LUBRICATION SYSTEM 341
QUICK FUEL SYSTEMS 349
WIGGINS QUICK FILL FUEL SYSTEM 349
BUCKEYE QUICK FUEL SYSTEM 353
KIM “HOTSTART SYSTEM” 355
SPECIAL TOOLS 359
AIR CONDITIONING SYSTEM 377
PRINCIPLES OF REFRIGERATION 378
AIR CONDITIONER SYSTEM COMPONENTS 380
ELECTRICAL CIRCUIT 382
SYSTEM SERVICING 383
INSTALLING MANIFOLD GAUGE SET 387
SYSTEM STABILIZATION 389
ADDING R-12 (PRIOR TO PERFORMANCE TEST) 389
SYSTEM PERFORMANCE TEST 391
DISCHARGING SYSTEM 390
FLUSHING AIR CONDITIONER COMPONENTS 388
SYSTEM REPAIR 392
HOSES, FITTINGS AND LINES 392
EXPANSION VALVE 392
RECEIVER DRIER 393
THERMOSTAT 393
CLUTCH 393
COMPRESSOR 393
CHECKING COMPRESSOR OIL LEVEL 393
EVACUATING THE SYSTEM 394
CHARGING THE SYSTEM 390
TROUBLESHOOTING 395
PREPARING FOR DIAGNOSIS 395
TROUBLESHOOTING CHART 397
OPERATOR’S CAB 405
TRUCK CAB 407
REMOVAL 407
INSTALLATION 410
OPERATOR COMFORT 413
OPERATOR SEAT 413
ADJUSTMENT INSTRUCTIONS 413
REMOVAL 413
INSTALLATION 413
DISASSEMBLY 414
INSPECTION 414
ASSEMBLY 414
HEATER/AIR CONDITIONER 416
WATER CONTROL VALVE 416
HEATER/AIR CONDITIONER 416
REMOVAL 416
INSTALLATION 418
OPERATOR CONTROLS AND INSTRUMENT PANEL 421
OPERATOR CONTROLS 421
INSTRUMENT PANEL 426
RETARDER OPERATION 428
INSTRUMENT PANEL (RIGHT SIDE) 429
CUMMINS ENGINE ELECTRONIC CONTROL SYSTEM 430
HEATER/AIR CONDITIONER CONTROLS 436
LUBRICATION AND SERVICE 437
LUBRICATION AND SERVICE 439
LUBRICATION SPECIFICATION CHARTS 439
SERVICE CAPACITIES 439
ANTI-FREEZE SPECIFICATIONS 439
OIL & GREASE SPECIFICATIONS 440
10 HOUR LUBRICATION AND MAINTENANCE CHECKS 441
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 443
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 445
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 447
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 449
ALPHABETICAL INDEX 451
SYSTEM SCHEMATICS 455
ELECTRIC SCHEMATIC 457
HYDRAULIC SYSTEM SCHEMATIC 469
ALLISON TRANSMISSION – HYDRAULIC SCHEMATIC 472

DESCRIPTION:

Komatsu 210M Dump Truck Shop Manual DG715 – PDF DOWNLOAD 

SERIAL SUFFIX : BFA40DA THRU EP 24501 THRU 24647

FOREWORD:

• This Service Manual is written for use by the service technician and is designed to help the technician
  become fully knowledgeable of the truck and all its systems in order to keep it running and in
  production. All maintenance personnel should read and understand the materials in this manual
  before performing maintenance and/or operational checks on the truck. All safety notices, warnings
  and cautions should be understood and followed when accomplishing repairs on the truck.
• The first section covers component descriptions, truck specifications and safe work practices, as well
  as other general information. The major portion of the manual pertains to disassembly, service and
  reassembly. Each major serviceable area is dealt with individually. For example: The disassembly,
  service and reassembly of the radiator group is discussed as a unit. The same is true of the engine
  and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly
  should be carried only as far as necessary to accomplish needed repairs.
• The illustrations used in this manual are, at times, typical of the component shown and may not
  necessarily depict a specific model.
  This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references
  to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position,
  unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the general information section and
  individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All
  torque specifications have ± 10% tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame in front of the right side front
  wheel and designates the Truck Model Number, Product Identification Number (vehicle serial
  number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
• The HAULPAK® Model designation consists of three numbers and one letter (i.e. 210M). The three
  numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter
  “E” designates an Electrical propulsion system.
• The Product Identification Number (vehicle serial number) contains information which will identify the
  original manufacturing bill of material for this unit. This complete number will be necessary for proper
  ordering of many service parts and/or warranty consideration.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other
  components. The vehicle design and application guidelines are sensitive to the total maximum Gross
  Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel &
  lubricants + the payload.

IMAGES PREVIEW OF THE MANUAL:

S.V 20/12/24